D.

Shuman July 10, 2012

Flange thickness, head to vessel main flanges:

inner radius
R i_pv = 0.68 m

max. allowable pressure

(gauge pressure)
P = 15.4 bar

The flange design for O-ring sealing (or other self energizing gasket such as helicoflex) is "flat-faced", with "metal
to metal contact outside the bolt circle". This design avoids the high flange bending stresses found in a raised face
flange (of Appendix 2) and will result in less flange thickness. The rules for this design are found only in sec VIII
division 1 under Appendix Y, and must be used with the allowable stresses of division 1. Flanges and shells will be
fabricated from 316Ti (ASME spec SA-240) stainless steel plate. Plate samples will be helium leak checked before
fabrication, as well as ultrasound inspected for flat laminar flaws which may create leak paths. The flange bolts and
nuts for a metal C-ring gasket seal will be inconel 718, (UNS N77180) as this is the highest strength non-corrosive
material allowed for bolting. For O-ring sealing we can use 304 bolts, temper B. We design the flanges for both
cases, using the parallel calculation mode of MathCAD in which the possible values for a parameter are expressed
as a matrix. Calculations are then performed in parallel for each row index. Where necessary (multiple vectors in an
expression) an arrow over the expression enforces this paralllelism
Maximum allowable material stresses, for sec VIII, division 1 rules from ASME 2010 Pressure Vessel
code, sec. II part D, table 2A (division 1 only):
Maximum allowable design stress for flange
Sf := Smax_316Ti_div1

Sf = 137.9 MPa

Sf = 2 10 psi

Maximum allowable design stress for bolts, from ASME 2010 Pressure Vessel code, sec. II part D, table 3
Inconel 718 (UNS N07718)
Smax_SA_574
Sb :=
Smax_N07718

Smax_N07718 := 37000psi

Smax_SA_574 := 33800psifor bolts => 5/8 in

233 MPa
Sb =

255.1

Smax_316_2 := 22000psi for bolts less than 3/4 in

From sec. VIII div 1, non-mandatory appendix Y for bolted joints having metal-to-metal contact outside of
bolt circle. First define, per Y-3:

hub thickness at flange (no hub)

g0 := t pv

g1 := t pv

g0 = 10 mm

corner radius:
g1 = 10 mm

r1 := max .25g1 , 5mm r1 = 5 mm

Flange OD
A := 1.48m
Flange ID
B := 2R i_pv
define:
B 1 := B + g1

B = 1.36 m
B 1 = 1.37 m

Bolt circle (B.C.) dia, C:

C := 1.43 m
Gasket dia

G := 2 Ri_pv + .65cm

G = 1.373 m O-ring mean radius as measured in CAD model:

68.65 2 = 137.3

Note: this diameter will be correct for Helicoflex gasket, but slightly higher for O-ring, which is fluid and
"transmits pressure" out to its OD, howqever the lower gasket unit force of O-ring more than compensates, as
per below:
Force of Pressure on head
2

H := .785G MAWPpv

H = 2.31 10 N

Sealing force, per unit length of circumference:

for O-ring, 0.275" dia., shore A 70 F= ~5 lbs/in for 20% compression, (Parker O-ring handbook); add 50%
for smaller second O-ring, and another 50% for 30% compression. Helicoflex and HTMS have equivalent
formulas using Y as the unit force term and gives several possible values.
for 4.78mm C-ring, M surface hardness:
recommended value for large diameter seals,
regardless of pressure or leak rate

N
Y2 := 65
mm
for O-ring only

lbf min value for our pressure

Y1 := 10
in and required leak rate (He)
for gasket diameter
Force is then either of:
Fm := Dj Y1

Dj := G
or

Fm = 7.554 10 N

N
Y1 = 1.751
mm

Dj = 1.373 m
Fj := Dj Y2
5

Fj = 2.804 10 N

Start by making trial assumption for number of bolts, nominal bolt dia., pitch, and bolt hole dia D,
C
maximum number of bolts possible,
n := 132
d b := 16mm
n max := trunc

using narrow washers:

2.0d b

Check strength restriction: db =>5/8in

n max = 140

d b 0.625in = 1
Choosing ISO fine thread for CS, extra fine for inconel, to maximize root dia.; thread depth is:

1.5 mm h := .6134 p
p t :=

3
t
1

0.92 mm
h3 =

0.613

25.4
18

= 1.411

using nomenclature and formulas from this chart at http://www.tribology-abc.com/calculators/metric-iso.htm

<---use h3 for 1.0 mm pitch

<--- use H1 for 1.5mm pitch

Bolt root dia. is then:

d 3 := d b 2h 3

d3 =

14.1598 mm

14.7732

Total bolt cross sectional area:

2
207.863 cm2
Ab := n d 3
Ab =

4
226.263
Check bolt to bolt clearance, here we use narrow thick washers (28mm OD) under the 24mm wide (flat to flat)
nuts (28mm is also corner to corner distance on nut), we adopt a minimum bolt spacing of 2x the nominal bolt
diameter (to give room for a 24mm socket) :
d w := 2d b

d w = 32 mm
C
actual bolt to bolt distance:

C n d w 0 = 1

Check nut, washer, socket clearance:

OD w := 2d b

0.5C 0.5B + g1 + r1 0.5OD w = 1

Check minimum bolt circle
0.5B + g1 + r1 + 0.5 d w 0.5C = 1
Flange hole diameter, minimum for clearance :

= 34.034 mm
this is for standard narrow washers, and for wrench
sockets which more than cover the nut width across
corners

Dtmin := d b + 2mm

Dtmin = 18 mm

We will thread some of these clearance holes for lift fixture bolts of size (db+4mm) to allow the head retraction
fixture to be bolted up the the flange. The effective diameter of these holes will be the average of nominal and
minimum diameters. To avoid thread interference with flange bolts, the flange studs will be machined to root
diameter per UG-12(b).in between threaded ends of 1.5x diameter in length. The actual clearance holes will be
db+2mm, depending on achievable tolerances, so as to allow threading where needed.
d lfb := d b + 4mm
from chart above, for 1.5mm thread pitch

H1 := .812mm

d min_lfb := d lfb 2 H1

d min_lfb = 1.838 cm

this will be max bolt hole size or

least material condition (LMC)

d min_lfb Dtmin = 1
effective threaded clearance hole diameter:

De := 0.5 d lfb + d min_lfb

De = 1.919 cm

Set:
Dt := De

Dt Dtmin = 1

Compute Forces on flange:

HG :=

Fm
Fj

HG =

h G := 0.5 C G

from Table 2-6 Appendix 2, Integral flanges

h G = 2.85 cm

HD := .785 B P

7.554 103

5
2.804 10

HD = 2.266 10 N

R . := 0.5 C B g1

R . = 2.5 cm

radial distance, B.C. to hub-flange intersection, int fl..

h D := R. + 0.5g1

h D = 3 cm

from Table 2-6 Appendix 2, Int. fl.

HT := H HD

HT = 4.353 10 N

h T := 0.5 R. + g1 + h G h T = 31.75 mm
Total Moment on Flange
M P := HD h D + HT h T + HG h G

6.958 104
J
MP =

4
7.736 10

Appendix Y Calculation
P = 15.4 bar
Choose values for plate thickness and bolt hole dia:
t := 4.15cm

D := Dt

from Table 2-6 Appendix 2, int. fl.

D = 1.919 cm

Going back to main analysis, compute the following quantities:

 :=

C + B1

= 1.022

2B1
A+C

a :=

1
rB :=
n

n D

AR :=

a = 1.062

2B 1

h C := 0.5 A C

h C = 2.5 cm

AR = 0.564

1 + AR

2AR
1 AR

atan

2
1 AR

h 0 :=

B g0

rB = 7.462 10

h 0 = 11.662 cm

We need factors F and V, most easily found in figs 2-7.2 and 7.3 (Appendix 2)
g1
since
these values converge to F := 0.90892 V := 0.550103
=1
g0
Y-5 Classification and Categorization
We have identical (class 1 assembly) integral ( category 1) flanges, so from table Y-6.1, our applicable
equations are (5a), (7) - (13), (14a), (15a), (16a)

JS :=

2 hD hC
+

+ rB
B1
a
1

(5a)
F' :=

g0 h 0 + F t

A = 1.48 m

F' = 2.806 10

JP :=

hD hC
+

+ rB
B1
a
6.958 104
N m
MP =

4
7.736 10
1

JP = 0.062

B = 1.36 m
2

K +1

A
K :=

JS = 0.083

K = 1.088 Z :=

Z = 11.854

K 1
hub stress correction factor for integral flanges, use f =1 for g1/g0=1 (fig 2-7.6)

f := 1

no spacer between flanges

t s := 0mm

l := 2t + t s + 0.5d b

strain length of bolt ( for class 1 assembly)

l = 9.1 cm

Y-6.1, Class 1 Assembly Analysis

http://www.hightempmetals.com/techdata/hitempInconel718data.php
Elastic constants:
E := ESS_aus

E = 193 GPa

EInconel_718 := 208GPa Ebolt :=

ECS

EInconel_718

Flange Moment due to Flange-hub interaction

M S :=

JP F' M P
3

t + JS F'

1.6 103
N m
MS =

3
1.8 10

Slope of Flange at I.D.

B :=

5.46
E t

J M + JP M P
3 S S

5.268 10 4

B =

4
5.856 10

Contact Force between flanges, at hC:

101.666 MPa

113.026

E B =

(7)

opening half gap =

(8)

B 3 cm =

0.016 mm

0.018

HC :=

2.718 106
N
HC =

6
3.021 10

MP + MS
hC

Bolt Load at operating condition:

5.035 106
N
6
5.612 10

Wm1 =

Wm1 := H + HG + HC

Operating Bolt Stress

Wm1
242.2
b :=
b =
MPa

248
Ab

0.965
rE =

0.928

E
rE :=
Ebolt

(9)

(10)

233
Sb =
MPa
255.1

(11)

elasticity factor

Design Prestress in bolts

1.159 h C ( M P + M S)

Si := b

a t l rE B1

236.8 MPa
Si =

241.8

(12)

120.8
SR_BC =
MPa
134.3

(13)

1.437 MPa
SR_ID =

1.597

(14a)

Radial Flange stress at bolt circle

6 MP + MS
SR_BC :=
2
t C n D

Radial Flange stress at inside diameter

MS
2F t
SR_ID :=
+ 6
h0 + F t
B1 t2
Tangential Flange stress at inside diameter
ST :=

t E B
B1

MS
2F t Z
h + F t 1.8
0
B1 t2

2.2 MPa
ST =

2.44

(15a)

Longitudinal hub stress

SH :=

h 0 E B f
2

g1
0.91 B1 V
g0

SH =

Y-7 Bolt and Flange stress allowables:

0
(a)
b Sb =
1

(b)
(1)

not applicable
1
SR_BC Sf =
1

233 MPa
Sb =

255.1

1
SH 1.5Sf =
1

(2)
(c)

17.288 MPa

19.22

Sn not applicable

(16a)

Sf = 137.9 MPa